Have I bitten off more that I can chew!!!! Nearly there

Show off your pristine van, restoration, or daily driver.
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Have I bitten off more that I can chew!!!! Nearly there

Post by HE0798 »

Well after a couple of months I thought I had better post some pics on here for posterity or my sanity one of the two.

Purchase my 56 Kombi from Dom on a bit of a beer and Ebay moment and after telling SWMBO if I'm going to do this then we are doing a splitty and not a bay

So here she is

The more observant of you will recognise her from Doms posts.

Image

First steps where to MOT her and she only failed on 4 things, exhaust, hole in the cab floor, number plate light not working and one other thing but I can remember.

So here starts my toil

First off ensure that I have the correct PPE, shorts check away we go!!! :wink:
Image

Floor came out first, too many patches to repair so a new floor is required.
Image

All the inside panels removed showing the polystyrene insulation below, so off that came.
Image

Corners are in bad shape the, previous repairs had simply being welded over and not done correctly so its got to go.
Image

The outrigger and jacking point completely rusted through to its got to come out.
Image

Decided to start on something else as the rust was starting to depress me

Image

Oh look more rust :roll:
Last edited by HE0798 on Wed Aug 14, 2013 10:00 am, edited 1 time in total.
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Re: Have I bitten off more that I can chew!!!!

Post by HE0798 »

Safaris removed
Image

Parcel shelf removed and I attacked the wiring :twisted:
Image

Started to remove the doors, the screws where rusted in tighter than a tight thing, broke two screw extractors in the process so had to cut a hinge free :cry:
Image

Next I attacked the front cross member which had been replaced with a piece of 4in pipe :), found all this mud inside the chassis, any suggestions on cleaning it out?
Image

Cut the cargo door sill open as it was rusted badly finding all this dirt inside
Image

Looks like half a Portuguese forest in the load space :)
Image
User avatar
vwJim
SSVC Committee Member
SSVC Committee Member
Posts: 20158
Joined: Thu Apr 24, 2003 6:05 pm
Location: under a bus in Hampshire...
Contact:

Re: Have I bitten off more that I can chew!!!!

Post by vwJim »

Plenty of welding ahead of you then.... Have fun.
Supplying quality in house designed items plus parts from SyncLink, Kennedy Clutches, & CB Performance. Also fitting service including modifications & mechanical upgrades.
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Re: Have I bitten off more that I can chew!!!!

Post by HE0798 »

That's an understatement, the problem I have at the moment is that the replacement panels are not playing ball, so the simple looking repairs just are not happening :wink:

Thanks for the well wishes
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Re: Have I bitten off more that I can chew!!!!

Post by HE0798 »

Removed the floor and found that the heater tube was missing also that the floor was from a 67 not the 56 it should be.
Image

Replaced the damage to the chassis from the damaged outriggers, also removed the 4" pipe to find the chassis plate damaged
Image

After a bit of shot blasting found more rust damage to the chassis so cut it out and replaced it.
Image

Found the reason for the exhaust failing the MOT :D
Image

Remove the lower inner valance, which fought every step of the way
Image

Had to cut a little section off the chassis to completely remove the old valance, made a nice job even if I say so myself :wink:
Image
Image
Image

Finally got to look a the A Pillar or what’s left of it, just can't quite work out the best way to fit the A Pillar
Image
Image
Image

Mounting the valance from the cab side, as soon as I get my head around the A Pillar issue
Image

Here is the problem with the A Pillar it’s just not flush as the original, just need to know if this is a one off or all Klassicfabs are the same.
Image
Image
User avatar
vwJim
SSVC Committee Member
SSVC Committee Member
Posts: 20158
Joined: Thu Apr 24, 2003 6:05 pm
Location: under a bus in Hampshire...
Contact:

Re: Have I bitten off more that I can chew!!!!

Post by vwJim »

HE0798 wrote:That's an understatement, the problem I have at the moment is that the replacement panels are not playing ball, so the simple looking repairs just are not happening :wink:

Thanks for the well wishes
Simple repairs.... what's that then?!?!
Supplying quality in house designed items plus parts from SyncLink, Kennedy Clutches, & CB Performance. Also fitting service including modifications & mechanical upgrades.
User avatar
andy f
SSVC Member
SSVC Member
Posts: 2106
Joined: Mon Oct 23, 2006 10:45 am
Location: Sunny Gosport on the South Coast

Re: Have I bitten off more that I can chew!!!!

Post by andy f »

looks like you got your work cut out there :wink:

I used the funky green kit on my front end. I'm pretty sure I had to "fettle" it a bit to get it right. Looking at yours I personally ( but I'm no expert ).......If you have good door gaps etc weld in the lower a post repairs in exactly the same place as your original and then "make" the joins fit the best way you can betweeen the front valance and the A post sections. i know it would be nice to have everything fit exactly as it would have originally but I just don't think it happens that way :(

In fact thinking about it I did end up putting cuts in the Apost repair sections where they meet the Valance to get it right


Good luck with it

Andy
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Re: Have I bitten off more that I can chew!!!!

Post by HE0798 »

Thanks for that Andy.

I was coming to the conclusion that I might have to cut it to fit.

I realise that getting new panels to fit to a 50 year old vehicle would not be a simple task, however I would expect newly manufactured panels to fit correctly :)

I'm waiting for Chris to come back to me at least we can give him some feed back to the supplier that the panels aren't quite fitting.


The next problem is that the wheel arches don't quite fit, I'm starting to think the van gaps are all over the place.

Now if only the weather stay fine I can get a little further :roll:
musclebus
Registered user
Posts: 3124
Joined: Wed Dec 15, 2004 4:21 pm
Location: Dorset 'BD Heaven & Hell'
Contact:

Re: Have I bitten off more that I can chew!!!!

Post by musclebus »

Hi Nick,

sorry I have not got back to you immediately regarding this but I had to take a day off work yesterday due to fatigue following a month of non-stop working 12-15 hour days without any time off ... I was getting frazzled :oops:

I have forwarded the link to this thread onto Gerson @ Klassicfab for his response and I will update you as soon as I have a response from him regarding it (in my experience of fitting these the outside lips / edges of the lower inner valance can be squeezed 1mm each side to meet the edges of the A Pillar connector piece for spot welding)

All the Best .... Chris
Please check our website for our remaining Klassicfab stock

http://www.musclebus.co.uk

musclebusclassics@gmail.com
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Re: Have I bitten off more that I can chew!!!!

Post by HE0798 »

Chris

No problems, I guessed that you may have been a little busy not an issue.

Its not so much the meeting it was more that the front edge didn't lie flush with the remainder of the valance, this would cause problems when I tried to fit the front valance as it wouldn't be flush.

I just didn't want to modify the parts to find out I had the wrong one or there had been a problem in production :)

As I mentioned above they just don't mate up like the bit I removed.

Hope you recover, I sypathise conpletly with you 15 hour days rule and the joys of owning your own buisness :roll:
nick
SSVC Member
SSVC Member
Posts: 4803
Joined: Sat Apr 26, 2003 2:32 am
Location: hairy ford

Re: Have I bitten off more that I can chew!!!!

Post by nick »

HE0798 wrote:Removed the floor and found that the heater tube was missing also that the floor was from a 67 not the 56 it should be.
has it had a new front clip at some stage in its life? of fried eggs cut into the front panel?
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Re: Have I bitten off more that I can chew!!!!

Post by HE0798 »

Nick.

To be honest the bodging I've found it could be a whole load of years :D

Basically its been over patched with a 67 floor, I found some of the older floor still in situe, the hand brake had been cut out of an older vehicle and patch welded in place.

Yes someone had cut the fish eye holes into the front.
nick
SSVC Member
SSVC Member
Posts: 4803
Joined: Sat Apr 26, 2003 2:32 am
Location: hairy ford

Re: Have I bitten off more that I can chew!!!!

Post by nick »

this is going to be a good project ... you look like you know what you are doing with a grinder and a welder... so i wish you good luck and keep the pics coming...
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Re: Have I bitten off more that I can chew!!!!

Post by HE0798 »

Grinding and Weldings the easy bit.

Its the putting back together and lining up thats the hard bit :)
HE0798
Registered user
Posts: 100
Joined: Tue May 25, 2010 2:07 pm

Re: Have I bitten off more that I can chew!!!!

Post by HE0798 »

Roll over jig turned up this morning :cheers:

This should be fun, no more crawling around under the chassis trying to weld and sand blast things :cheers:
Post Reply